U.S. patent application number 13/331503 was filed with the patent office on 2013-06-20 for mattress support element.
The applicant listed for this patent is Justin Lall. Invention is credited to Justin Lall.
Application Number | 20130152305 13/331503 |
Document ID | / |
Family ID | 48608638 |
Filed Date | 2013-06-20 |
United States Patent
Application |
20130152305 |
Kind Code |
A1 |
Lall; Justin |
June 20, 2013 |
MATTRESS SUPPORT ELEMENT
Abstract
A mattress support element is presented formed from a
combination of natural plant material and processed plant material.
The processed plant material forms a framework of cells. Each cell
contains one or more freestanding cylindrical sections. The
cylindrical sections provide limited range piston-like movement
within the cell, and may be made of natural plant materials. The
cylindrical sections and the framework rest on a fabric base. The
cylindrical sections stand taller than the framework. A ceiling
layer of fabric overlays the cylindrical sections and framework,
thereby constraining the cylindrical sections to remain in their
respective cells. One or more layers of upper padding or cushioning
may rest over the support element, and one or more layers of lower
padding may rest under the support element.
Inventors: |
Lall; Justin; (Valley View,
TT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lall; Justin |
Valley View |
|
TT |
|
|
Family ID: |
48608638 |
Appl. No.: |
13/331503 |
Filed: |
December 20, 2011 |
Current U.S.
Class: |
5/400 |
Current CPC
Class: |
A47C 27/148 20130101;
A47C 27/122 20130101; A47C 27/127 20130101 |
Class at
Publication: |
5/400 |
International
Class: |
A47C 19/02 20060101
A47C019/02 |
Claims
1. A mattress support element, comprising: a first containment
layer; a second containment layer; and a support layer disposed
between said first containment layer and said second containment
layer comprising: a plurality of load bearing elements; and a frame
comprising a plurality of cells, wherein each of said load bearing
elements is at least partially contained within one of said
plurality of cells, wherein said frame is configured to
substantially restrict motion of said plurality of load bearing
elements in a horizontal plane, and to substantially allow motion
of said plurality of load bearing elements along a vertical axis,
and said first containment layer and said second containment layer
are configured to limit the range of motion of said load bearing
elements along said vertical axis.
2. The mattress support element of claim 1, wherein said plurality
of load bearing elements are substantially cylindrical in
shape.
3. The mattress support element of claim 2, wherein said load
bearing elements are formed of natural plant material.
4. The mattress support element of claim 3, wherein said natural
plant material is one of the group consisting of reed and
bamboo.
5. The mattress support element of claim 2, wherein said plurality
of cells form a grid.
6. The mattress support element of claim 2, wherein a first height
of each of said plurality of load bearing elements is greater than
a second height of each of said plurality of cells housing said
load bearing elements.
7. The mattress support element of claim 5, wherein said grid rests
substantially on said first containment layer.
8. The mattress support element of claim 1, wherein said frame is
formed of processed plant material.
9. The mattress support element of claim 1, wherein each cell of
said plurality of cells houses at most one of said plurality of
load bearing elements.
10. The mattress support element of claim 1, wherein said first
containment layer and said second containment layer comprise one of
the group consisting of foam, gel, fiber, air bladders, and
fabric.
11. The mattress support element of claim 1, further comprising: a
first pad adjacent to said first containment layer; and a second
pad adjacent to said second containment layer.
12. A mattress support element, comprising: a first containment
layer; a second containment layer; and a support layer disposed
between said first containment layer and said second containment
layer comprising: a plurality of bamboo cylinders with a first
height spanning between said first containment layer to said second
containment layer; and a frame with a second height less than said
first height formed of processed plant material, comprising a
plurality of cells arranged in a grid, wherein each cell houses one
of said plurality of bamboo cylinders, wherein said first
containment layer and said second containment layer contain each of
said bamboo cylinders within its respective one of said plurality
of cells, and each cell is configured to substantially restrict
lateral movement one of each of said housed bamboo cylinders.
13. A method for making a mattress support element, comprising the
steps of: providing a first containment layer; forming a frame
comprising a plurality of cells, wherein said frame has a first
height; attaching said first containment layer to a first side of
said frame; inserting at least one of a plurality of load bearing
elements within each of said plurality of cells, wherein each of
said plurality of load bearing elements has a second height greater
than said first height; providing a second containment layer; and
attaching said second containment layer to a second side of said
frame.
14. The method of claim 13, wherein said frame is formed of a
processed plant material.
15. The method of claim 13, wherein said plurality of load bearing
elements is formed of a natural plant material.
16. The method of claim 15, wherein each of said plurality of load
bearing elements is substantially cylindrical.
17. The method of claim 16, wherein said natural plant material is
one of the group consisting of reed and bamboo.
18. The method element of claim 13, wherein said first containment
layer and said second containment layer comprise one of the group
consisting of foam, gel, fiber, and fabric.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to bedding and more
particularly, is related to a mattress support element.
BACKGROUND OF THE INVENTION
[0002] Support elements for existing mattresses are typically
provided by oil-based chemicals in the form of foams, metal, for
example springs, air, and liquids, among other elements. Even the
air and liquid support elements are generally contained by oil
based materials, for example, plastics. However, metallic and oil
based materials may be disadvantageous, due to, for example, global
procurement vulnerability, price uncertainty, and negative
environmental effects. These negative environmental effects occur
in processing the materials, for example oil extraction and
refining, as well as in waste management, for example, disposing of
discarded mattresses containing oil products and chemicals.
[0003] The support element of a mattress provides firmness and
structure to a surface that may yield and suspend the weight of a
person without binding or restricting circulation. Desirable
characteristics include light weight, low cost, breathability, and
durability. It is also desirable for a mattress to be configurable
to personal taste, for example, firmness, softness, springiness,
and how well the mattress dampens vibrations and/or isolates
movements from one section of the mattress from another section of
the mattress. Light weight may be desirable for reducing shipping
costs, assisting portability, and ease of manipulating when
changing bedding. Breathability may be desirable to avoid buildup
of moisture and resulting mold or mildew.
[0004] Durability refers to a mattress not degrading over time, so
it may not perform as it did when new. A durable mattress is
generally usable over a longer period of time.
[0005] Therefore, there is a need in the industry for a mattress
that addresses some of the shortcomings or issues described
above.
SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention provide a mattress
support element and method for producing a mattress. In general the
present invention is directed to a mattress support element using a
combination of natural plant material and processed plant material.
The processed plant material, for example, paper, forms a grid or
matrix of cells. Each cell contains one or more freestanding
cylindrical sections. The cylindrical sections may be made of
natural plant materials, for example, segments of reed or bamboo.
The cylindrical sections and the grid rest on a base, for example,
a fabric base. The cylindrical sections stand taller than the grid.
A ceiling layer of fabric overlays the cylindrical sections and
grid, thereby constraining the cylindrical sections to remain in
their respective cells. One or more layers of upper padding or
cushioning may rest over the support element, and one or more
layers of lower padding may rest under the support element.
[0007] Briefly described, in architecture, a first aspect of the
present invention is directed to a mattress support element,
including a first containment layer, a second containment layer,
and a support layer disposed between the first containment layer
and the second containment layer. The support layer includes a
frame with at least one cell, wherein each cell houses at least one
of a plurality of load bearing elements. The frame is configured to
substantially restrict motion of the plurality of load bearing
elements in a horizontal plane, and to substantially allow motion
of the plurality of load bearing elements in a vertical axis. The
first containment layer and second containment layer are configured
to limit the range of motion of the load bearing elements along the
vertical axis.
[0008] Embodiments according to the first aspect may include where
the load bearing elements are substantially cylindrical in shape.
The load bearing elements may be formed of natural plant material,
for example, reed and/or bamboo. The plurality of cells may form a
grid, and wherein a first height of each of the plurality of load
bearing elements is greater than a second height of the cell
housing the load bearing element. The support element may also
include a first pad adjacent to the first containment layer and a
second pad adjacent to the second containment layer.
[0009] A second aspect of the present invention is directed to a
mattress support element having a first containment layer, a second
containment layer, and a support layer disposed between the first
containment layer and the second containment layer. The support
layer includes a plurality of bamboo cylinders with a first height
spanning between the first containment layer to the second
containment layer, and a frame with a second height less than the
first height formed of processed plant material, including a
plurality of cells arranged in a grid. Each cell houses one of the
plurality of bamboo cylinders. The first containment layer and the
second containment layer contain each of the bamboo cylinders
within its respective cells, and each cell is configured to
substantially restrict lateral movement one of each of the housed
bamboo cylinders.
[0010] Briefly described, in architecture, a third aspect of the
present invention is directed to a method including the steps of
providing a first containment layer, forming a frame comprising a
plurality of cells, wherein the frame has a first height, attaching
the first containment layer to a first side of the frame, inserting
at least one of a plurality of load bearing elements within each of
the plurality of cells, wherein each of the plurality of load
bearing elements has a second height greater than the first height,
providing a second containment layer, and attaching the second
containment layer to a second side of the frame.
[0011] Other systems, methods and features of the present invention
will be or become apparent to one having ordinary skill in the art
upon examining the following drawings and detailed description. It
is intended that all such additional systems, methods, and features
be included in this description, be within the scope of the present
invention and protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings are included to provide a further
understanding of the invention, and are incorporated in and
constitute a part of this specification. The drawings illustrate
embodiments of the invention and, together with the description,
serve to explain the principals of the invention.
[0013] FIG. 1 is a schematic diagram of an exemplary embodiment of
a mattress support element.
[0014] FIG. 2 is a schematic diagram of an exemplary embodiment of
a mattress in exploded view.
[0015] FIG. 3A is schematic diagram of a mattress support with no
weight load.
[0016] FIG. 3B is schematic diagram of a mattress support subject
to a weight load.
[0017] FIG. 4A is a schematic diagram of a mattress support element
having one load bearing element per cell.
[0018] FIG. 4B is a schematic diagram of a first example of a
mattress support element having multiple load bearing elements per
cell.
[0019] FIG. 4C is a schematic diagram of a second example of a
mattress support element having multiple load bearing elements per
cell.
[0020] FIG. 4D is a schematic diagram of a mattress support element
having non-rectangular cells.
[0021] FIG. 4E is a schematic diagram of a mattress support element
having non-uniform sized cells and load bearing elements.
[0022] FIG. 5 is a schematic diagram of a second exemplary
embodiment of a mattress support element.
DETAILED DESCRIPTION
[0023] Reference will now be made in detail to embodiments of the
present invention, examples of which are illustrated in the
accompanying drawings. Wherever possible, the same reference
numbers are used in the drawings and the description to refer to
the same or like parts.
[0024] FIG. 1 is a schematic diagram of a first exemplary
embodiment of a mattress support element 100. The core of the
support element 100 is a matrix or grid 120. The matrix 120
contains a plurality of cells, each cell containing at least one
load bearing element 140. The load bearing elements 140 are
generally taller than the matrix 120, and stand so the tops of the
load bearing elements 140 rise above the matrix 120, protruding
outward above the matrix 120 so the load bearing elements 140 are
first to bear the load of an object or person subjecting weight to
the support element 100. Load bearing characteristics of the
support element 100 are described further below.
[0025] The matrix 120 is generally a framework containing load
bearing elements 140. The matrix 120 at least partially restricts
movement of the load bearing elements 140 in a first direction and
a second direction, for example, a horizontal plane, and allows
movement of the load bearing elements 140 in a third direction, for
example, a vertical axis.
[0026] The load bearing elements 140 as shown in the first
embodiment are substantially cylindrical in shape. However, there
is no objection to load bearing elements 140 with other shapes, for
example, but not limited to, rectangular or hexagonal blocks. The
load bearing elements 140 may be substantially hollow, or may be
solid. Hollow load bearing elements 140 may be preferable for
weight and air flow considerations.
[0027] FIG. 2 is a schematic diagram of an exemplary embodiment of
a mattress 200 incorporating a support element 100 in exploded
view. The matrix 120 rests upon a lower containing fabric 265. The
lower containing fabric 265 is affixed to the bottom of the matrix
120. It is desirable that the lower containing fabric 265 have
elastic properties, for example, to provide resistance to the
movement of the load bearing elements 140. The lower containing
fabric 265 may be affixed to a lower perimeter of each cell, may be
affixed to an outer lower perimeter of the matrix 120, or may be
affixed to a lower perimeter of a group of cells and may also rest
unfixed to the matrix 120. The lower containing fabric 265 is
adjacent to a lower pad 260. The lower pad 260 generally compresses
under the pressure of a load. The lower pad 260 may be made from,
for example, foam, gel, cotton padding, or other such resilient
materials.
[0028] Load bearing elements 140 are located inside cells of the
matrix 120. Under the first embodiment each cell of the matrix 120
houses a single load bearing element 140. The load bearing elements
140 rest directly upon the lower containing fabric 265. At least a
portion of the weight of each load bearing element 140 may be
supported by the lower pad 260. Therefore, the lower pad 260
generally compresses and deforms beneath the load bearing elements
140.
[0029] An upper containing fabric 215 is affixed to the top side of
the matrix 120. The upper containing fabric 215 may be affixed to
an upper perimeter of each cell, may be affixed to an outer upper
perimeter of the matrix 120, or may be affixed to an upper
perimeter of a group of two or more cells, to one or more load
bearing elements 140, and may also rest unfixed. It is desirable
that the upper containing fabric 215 have elastic properties, for
example, to provide resistance to the movement of the load bearing
elements 140.
[0030] As described previously, the load bearing elements 140 are
generally taller than the height of the matrix 120. When the upper
containing fabric 215 and the lower containing fabric 265 are
affixed to the matrix 120, the upper containing fabric 215 and the
lower containing fabric 265 exert opposing forces upon the load
bearing elements 140, so that the load bearing elements 140 may be
described as being suspended within the cells of the matrix
120.
[0031] An upper pad 210 is adjacent to the upper containing fabric
215. The upper pad 210 may exert additional downward force upon the
load bearing elements 140. The upper pad 210 may be made from, for
example, foam, gel, cotton padding, or other such resilient
materials. Therefore, the upper pad 210 generally compresses and
deforms when pressed against the load bearing elements 140 and/or
the matrix 120.
[0032] It should be noted that while FIG. 2 depicts an upper pad
210 and a lower pad 260, there is no objection to an embodiment of
the support element 100 without an upper pad 210 and/or a lower pad
260. For example, the support element 100 may be utilized between
external components that perform load dispersion functions similar
to the upper pad 210 and the lower pad 260.
[0033] The mattress 200 is depicted as substantially symmetrical
around a horizontal plane. However, there is no objection to
embodiments of the mattress 200 where, for example, the lower pad
260 is thicker than the upper pad 210, or the upper pad 210 is
thicker than the lower pad 260. Indeed, such variations may
contribute to suiting the preferences of a range of
individuals.
[0034] FIG. 3A is a schematic diagram of the mattress 200 with no
weight load. Note the upper containing fabric 215 and the lower
containing fabric 265 are not shown for purposes of clarity. The
load bearing elements 140 are constrained from moving laterally be
the matrix 120. The load bearing elements 140, while partially
constrained by the upper containing fabric 215 (FIG. 2) and the
lower containing fabric 265 (FIG. 2), are able to move in a limited
vertical range of motion within the matrix 120 cell. When no weight
is placed upon the mattress 200, the upper pad 210 and the lower
pad 260 are generally uncompressed, and the load bearing elements
140 remain generally aligned in a horizontal plane.
[0035] FIG. 3B is schematic diagram of a mattress 200 subject to a
weight load. When a weight is applied to the top surface of the
mattress 200, the weight is absorbed by and distributed through the
mattress in several different ways. The weight is depicted by heavy
black arrows. The top pad 210 compresses directly under the weight.
The top pad 210 exerts a downward force upon adjacent load bearing
elements 140, causing a piston-like downward displacement of the
load bearing elements 140 within the cells of the matrix 120. Load
bearing elements 140 subject to greater force of weight, such as
the center load bearing element 140 in FIG. 3B, display greater
vertical displacement than adjacent load bearing elements 140.
Similarly, the load bearing elements not subject to the weight upon
the mattress 200, such as the leftmost and rightmost load bearing
elements 140, may exhibit little or no vertical displacement. Of
course, additional forces may come into play upon a load bearing
element 140, for example the force of the upper containing fabric
215 being displaced in an adjacent cell.
[0036] The vertical range of upward and downward motion of the load
bearing elements 140 relative to the matrix 120 is generally
restricted by elements external to the mattress support element
100, for example, the upper containing fabric 215, the lower
containing fabric 265, the upper pad 210 and the lower pad 260.
However, there is no objection to the load bearing elements being
range restricted by other objects or forces. It is desirable that
the range of motion of the load bearing elements 140 relative to
the matrix be limited to at least contain the load bearing elements
within the cells of the matrix 120.
[0037] For specific applications, it may be desirable to restrict
the vertical range of the load bearing elements 140 to specific
tolerances. For example, if a load bearing element 140 is six
inches tall, it may be desirable to restrict the load bearing
element 140 from extending more than three inches above the matrix
120 or three inches below the matrix 120. Such range restrictions
may be accomplished, for example, by affixing a raised belt around
the center of the load bearing element 140, and by extending a rim
at the top and bottom of each cell in the matrix 120, where the top
rim restricts the raised belt from extending further above the top
of the matrix, and the bottom rim restricts the raised belt from
extending further below the bottom of the matrix. Persons with
ordinary skill in the art will recognize that this is just one of
several mechanisms that may be used to restrict the vertical range
of motion of a load bearing element 140 within a cell of the matrix
120.
[0038] As load bearing elements 140 are forced downward through
cells of the matrix 120, the load bearing elements 140 in turn
exert downward force upon the lower pad 260. The lower pad 260
compresses somewhat, and may also bulge downward (not shown)
[0039] Of course, there is no objection to additional cushioning or
load bearing layers above the upper pad 210 and/or below the lower
pad 260. Similarly, there is no objection to a mattress employing
two or more support elements 100, for example, in layers, possible
with additional padding interleaved. In such an embodiment, there
is further no objection to each layered support element 100 having
different configurations, for example, width and/or flexibility.
Different configurations of support element 100 are described
further below.
[0040] Under the first embodiment, the matrix 120 is generally
rigid. This limits the amount the surface of the mattress 210 may
be compressed. However, there is no objection to embodiments where
the matrix 120 may have some flexibility, therefore allowing
additional downward compression of the mattress 200. Similarly, the
load bearing elements 140 may be substantially structurally rigid,
in that flexible support provided by the mattress 200 surface to a
contoured shape on the mattress 200 is substantially provided by
the movement of the load bearing elements 140 within the grid 120
as contained by the containing fabric 215, 265 (FIG. 2), rather
than by the compression of the load bearing elements 140. This
contrasts with, for example, a spring mattress, where variable
support is provided by compression of individually compressible
springs. While the load bearing elements 140 may compress somewhat
under the load of a weight, such compression is at most a secondary
flexible support mechanism, and there is no objection to
embodiments where the load bearing elements 140 exhibit no
compression characteristics.
[0041] The configuration of the support element may contribute to
how it responds to weight loads. Several characteristics may be
altered, for example, the height of the matrix 120, the height of
the load bearing elements 140 in relation to the matrix 120, the
width of the cells and the corresponding diameter of the load
bearing elements 140. For example, smaller diameter load bearing
elements 140 may result in depressions upon the mattress surface
being more localized, while wider load bearing elements 140 may
result in larger local depressions. The diameter of load bearing
elements may contribute to the sensation of support provided by the
mattress. Other variable elements include the flexibility of the
upper containing fabric 215 and the lower containing fabric 265.
Further there is no objection to embodiments where the thickness of
the matrix 120 is not uniform across the mattress 200, and/or the
load bearing elements 140 do not have uniform height throughout the
mattress 200. For example, it may be desirable for the mattress 200
to exhibit a crown, where the mattress 200 is thicker in the center
region. For another example, a mattress 200 may be formed with a
well depression in the center, for an application such as a seat
cushion. Persons having ordinary skill in the art will appreciate
similar applications for non-uniform height variations for the
matrix 120 and/or the load bearing elements 140.
[0042] Other types of variations are possible. For example, FIG. 4A
depicts a mattress support element 100 having one load bearing
element per cell, while FIGS. 4B and 4C each depict a mattress
support element 100 having multiple load bearing elements 140 per
cell. Each cell may contain support elements that are arranged in
single lines (FIG. 4B), or support elements may be arranged
honeycomb fashion, as shown in FIG. 4C. Other geometric
arrangements of load bearing elements 140 within a cell are
possible. The cells and support elements 140 within a matrix need
not be equi-distant, evenly spaced, or uniform in size. For
example, FIG. 4E shows a mattress element 100 with a group of small
cells surrounded by a group of large cells, with smaller load
bearing elements 440 within the small cells, and larger load
bearing elements 442 within the larger cells. Such an arrangement
may be desirable, for example, to provide a support element 100
having regions with different levels of firmness.
[0043] Under the first embodiment, the matrix 120 is depicted as a
rectangular grid. However, there is no objection to other
geometrical arrangements for a matrix 120. For example, FIG. 4D is
a schematic diagram of a mattress support element having
non-rectangular cells. While FIG. 4D shows non-rectangular cells
with one load bearing element 140 per cell, there is no objection
to a support element 100 having non-rectangular cells with more
than one load bearing element 140 per cell. The non-rectangular
cells of FIG. 4D are depicted as triangular. However, other cell
shapes may be used, for example, hexagonal cells may form a
honeycomb shaped matrix 120 that allows, for example, a higher
density of load bearing elements than rectangular or triangular
cells.
[0044] Under a second exemplary embodiment of a mattress support
element 500, as shown in FIG. 5, some cells 530 of a matrix 120
contains a plurality of cells 530. Some cells 530 of the matrix 120
contain load bearing elements 140, and some cells 530 do not
contain load bearing elements 140. Under the second exemplary
embodiment, areas of the mattress support element 500 intended to
support greater weight loads may be more densely populated with
load bearing elements 140, while areas of the mattress support
element 500 that may be intended to support lighter loads may be
more sparsely populated by load bearing elements 140.
[0045] While the above description has generally referred to the
invention in the context of a mattress, there is no objection to
other applications, for example as mattress foundations or bases,
box springs, seat cushions, or any other load bearing purpose.
Natural Materials
[0046] The materials for the matrix 120 and the load bearing
elements 140 may be selected to suit different requirements. For
example, lowest cost, lowest weight, local availability, maximum
durability, and other requirements. A low cost, readily available
material for the load bearing elements 140 may be, for example, PVC
tubing.
[0047] In an embodiment where the criteria is for the materials to
be environmentally friendly, the criteria may apply both in
producing the materials for construction and for disposing of the
materials after the end of life of the mattress. For production,
therefore, use of a renewable resource for the matrix 120 and the
load bearing elements 140 is desirable. Similarly, it is desirable
that the materials be biodegradable to minimize the environmental
impact of disposing of the materials after the end of life of the
mattress.
[0048] The matrix 120 may be formed of a processed plant material,
for example, paper products such as cardboard. The geometric shape
of the matrix 120 generally contributes to the strength and
structural rigidity of the matrix 120. However, other processed
plant materials, such as string, twine and/or rope may be used to
maintain the structural integrity of the matrix 120. Similarly,
processed plant material may be used for the load bearing elements
140. Alternatively, natural plant material may be used for the load
bearing elements 140. For example, a load bearing element 140 may
be formed of a cut section of bamboo or reed.
[0049] It may be particularly advantageous that the natural
materials and the processed plant materials be locally produced,
minimizing the costs for transporting materials and import tariffs.
The ability to select among several different materials depending
upon costs and availability may also result in an end product less
susceptible to price fluctuations due to external cost pressures.
For example, the costs of locally produced plant products and
natural plant materials may generally be more stable than petroleum
based mattress materials, for example foams and plastics.
[0050] It will be apparent to those skilled in the art that various
modifications and variations can be made to the structure of the
present invention without departing from the scope or spirit of the
invention. In view of the foregoing, it is intended that the
present invention cover modifications and variations of this
invention provided they fall within the scope of the following
claims and their equivalents.
* * * * *